check engine TOYOTA CAMRY 2000 Service Repair Manual

S03789
1
4
6
5
2
3
N00991
P03166
N00924
N00993
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±91
1263 Author: Date:
13. REMOVE ENGINE BALANCER
(a) Uniformly loosen and remove the 6 bolts in several
passes, in the sequence shown.
(b) Remove the engine balancer and spacers.
14. CHECK CONNECTING ROD THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while mov-
ing the connecting rod back and forth.
Standard thrust clearance:
0.160 ± 0.312 mm (0.0063 ± 0.0123 in.)
Maximum thrust clearance: 0.35 mm (0.0138 in.)
If the thrust clearance is greater than maximum, replace the
connecting rod assembly. If necessary, replace the crankshaft.
15. REMOVE CONNECTING ROD CAPS AND CHECK OIL
CLEARANCE
(a) Check the matchmarks on the connecting rod and cap to
ensure correct reassembly.
(b) Remove the 2 connecting rod cap nuts.
(c) Using a plastic±faced hammer, lightly tap the connecting
rod bolts and lift off the connecting rod cap.
HINT:
Keep the lower bearing inserted with the connecting rod cap.
(d) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(e) Clean the crank pin and bearing.
(f) Check the crank pin and bearing for pitting and scratches.
If the crank pin or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.

S05989
N00993
P00598
P00105
481062
1
5
9
7
3
S06014
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±93
1265 Author: Date:
16. REMOVE PISTON AND CONNECTING ROD AS-
SEMBLIES
(a) Using a ridge reamer, remove all the carbon from the top
of the cylinder.
(b) Cover the connecting rod bolts with a short piece of hose
to protect the crankshaft from damage.
(c) Push the piston, connecting rod assembly and upper
bearing through the top of the cylinder block.
HINT:

Keep the bearings, connecting rod and cap together.

Arrange the piston and connecting rod assemblies in the
correct order.
17. CHECK CRANKSHAFT THRUST CLEARANCE
Using a dial indicator, measure the thrust clearance while prying
the crankshaft back and forth with a screwdriver.
Standard thrust clearance:
0.020 ± 0.220 mm (0.0008 ± 0.0087 in.)
Maximum thrust clearance: 0.30 mm (0.0118 in.)
If the thrust clearance is greater than maximum, replace the
thrust washer as a set.
Thrust washer thickness:
2.440 ± 2.490 mm (0.0961 ± 0.0980 in.)
18. REMOVE MAIN BEARING CAPS AND CHECK OIL
CLEARANCE
(a) Uniformly loosen and remove the 10 main bearing cap
bolts in several passes, in the sequence shown.
(b) Using 2 screwdrivers, pry out the main bearing cap, and
remove the 5 main bearing caps, 5 lower bearings and 2
lower thrust washers (No.3 main bearing cap only).
HINT:

Keep the lower bearing and main bearing cap together.

Arrange the main bearing caps and lower thrust washers
in the correct order.
(c) Lift out the crankshaft.

N01000
Plastigage
P00104
10 159
73
4
86
2
N00988
EM±94
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1266 Author: Date:
HINT:
Keep the upper bearing and upper thrust washers together with
the cylinder block.
(d) Clean each main journal and bearing.
(e) Check each main journal and bearing for pitting and
scratches.
If the journal or bearing is damaged, replace the bearings. If
necessary, grind or replace the crankshaft.
(f) Place the crankshaft on the cylinder block.
(g) Lay a strip of Plastigage across each journal.
(h) Install the main bearing caps. (See page EM±107)
NOTICE:
Do not turn the crankshaft.
(i) Remove the main bearing caps.
(See steps (a) and (b))
(j) Measure the Plastigage at its widest point.
Standard clearance:
No.3 STD
U/S 0.250.025 ± 0.044 mm (0.0010 ± 0.0017 in.)
0.027 ± 0.067 mm (0.0011 ± 0.0026 in.)
Others STD
U/S 0.250.015 ± 0.034 mm (0.0006 ± 0.0013 in.)
0.019 ± 0.059 mm (0.0007 ± 0.0023 in.)
Maximum clearance: 0.08 mm (0.0031 in.)
HINT:
If replacing the cylinder block subassembly, the bearing stan-
dard clearance will be:
No.30.027 ± 0.054 mm (0.0001 ± 0.0021 in.)
Others0.017 ± 0.044 mm (0.0007 ± 0.0017 in.)
If the oil clearance is greater than maximum, replace the bear-
ings. If necessary, grind or replace the crankshaft.

A06590
A06589
A06587
A01774
A01775
EM±96
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1268 Author: Date:
20. CHECK FIT BETWEEN PISTON AND PISTON PIN
Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
21. REMOVE PISTON RINGS
(a) Using a piston ring expander, remove the No.1 and No.2
piston rings.
(b) Remove the 2 side rails and oil ring expander by hand.
HINT:
Arrange the piston rings in correct order only.
22. DISCONNECT CONNECTING ROD FROM PISTON
(a) Using a small screwdriver, pry out the 2 snap rings.
(b) Gradually heat the piston to 80 ± 90°C (176 ± 194°F).
(c) Using a plastic±faced hammer and brass bar, lightly tap
out the piston pin and remove the connecting rod.
HINT:

The piston and pin are a matched set.

Arrange the pistons, pins, rings, connecting rods and
bearings in the correct order.

EM08J±03
S05970
Z19127
S05987
S05569
No.1 No.2 No.3 No.4Mark 1, 2 or 3
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±97
1269 Author: Date:
INSPECTION
1. CLEAN CYLINDER BLOCK
(a) Remove the gasket material.
Using a gasket scraper, remove all the gasket material
from the top surface of the cylinder block.
(b) Clean the cylinder block.
Using a soft brush and solvent, thoroughly clean the cylin-
der block.
2. INSPECT CYLINDER BLOCK
(a) Inspect for flatness.
Using a precision straight edge and feeler gauge, mea-
sure the surfaces contacting the cylinder head gasket for
warpage.
Maximum warpage: 0.05 mm (0.0020 in.)
If warpage is greater than maximum, replace the cylinder block.
(b) Visually check the cylinder for vertical scratches.
If deep scratches are present, rebore all the 4 cylinders and re-
place all the 4 pistons. (See page EM±104) If necessary, re-
place the cylinder block.
(c) Inspect the cylinder bore diameter.
HINT:
There are 3 sizes of the standard cylinder bore diameter,
marked º1º, º2º and º3º accordingly. The mark is stamped on the
top of the cylinder block.

A06594
Z00064
Z00065
EM7538
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±101
1273 Author: Date:
If the end gap is greater than maximum, replace the piston ring.
If the end gap is greater than maximum, even with a new piston
ring, rebore all the 4 cylinders (see page EM±104) or replace
the cylinder block.
(d) Inspect the piston pin fit.
At 60°C (140°F), you should be able to push the piston
pin into the piston pin hole with your thumb.
(e) Using a rod aligner and feeler gauge, check the connect-
ing rod alignment.
(1) Check for bend.
Maximum bend:
0.05 mm (0.0020 in.) per 100 mm (3.94 in.)
If bend is greater than maximum, replace the connecting rod as-
sembly.
(2) Check for twist
Maximum twist:
0.15 mm (0.0059 in.) per 100 mm (3.94 in.)
If twist is greater than maximum, replace the connecting rod as-
sembly.
(f) Inspect the piston pin oil clearance.
(1) Using a caliper gauge, measure the inside diameter
of the connecting rod bushing.
Bushing inside diameter:
22.005 ± 22.017 mm (0.8663 ± 0.8668 in.)

EM0227
P13428
A02826
15 mm
(0.59 in.)
EM±102
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1274 Author: Date:
(2) Using a micrometer, measure the piston pin diame-
ter.
Piston pin diameter:
21.997 ± 22.009 mm (0.8660 ± 0.8665 in.)
(3) Subtract the piston pin diameter measurement from
the bushing inside diameter measurement.
Standard oil clearance:
0.005 ± 0.011 mm (0.0002 ± 0.0004 in.)
Maximum oil clearance: 0.05 mm (0.0020 in.)
If the oil clearance is greater than maximum, replace the bush-
ing. (See page EM±104) If necessary, replace the piston and
piston pin as a set.
(g) Inspect the connecting rod bolts.
(1) Install the cap nut to the connecting rod bolt. Check
that the cap nut can be turned easily by hand to the
end of the thread.
(2) If the cap nut cannot be turned easily, measure the
outside diameter of the connecting rod bolt with a
vernier caliper.
Standard diameter:
7.860 ± 8.000 mm (0.3094 ± 0.3150 in.)
Minimum diameter: 7.60 mm (0.2992 in.)
HINT:
If the location of this area cannot be judged by visual inspection,
measure the outer diameter at the location shown in the illustra-
tion.
If the outside diameter is less than minimum, replace the con-
necting rod bolt and nut as a set.

P00118
EM3553
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±103
1275 Author: Date:
5. INSPECT CRANKSHAFT
(a) Inspect for circle runout.
(1) Place the crankshaft on V±blocks.
(2) Using a dial indicator, measure the circle runout at
the center journal.
Maximum circle runout: 0.06 mm (0.0024 in.)
If the circle runout is greater than maximum, replace the crank-
shaft.
(b) Inspect the main journals and crank pins.
(1) Using a micrometer, measure the diameter of each
main journal and crank pin.
Main journal diameter:
STD54.988 ± 55.003 mm (2.1653 ± 2.1655 in.)
U/S 0.2554.745 ± 54.755 mm (2.1553 ± 2.1557 in.)
Crank pin diameter:
STD51.985 ± 52.000 mm (2.0466 ± 2.0472 in.)
U/S 0.2551.745 ± 51.755 mm (2.0372 ± 2.0376 in.)
If the diameter is not as specified, check the oil clearance. (See
page EM±86) If necessary, grind or replace the crankshaft.
(2) Check each main journal and crank pin for taper
and out±of±round as shown.
Maximum taper and out±of±round:
0.02 mm (0.0008 in.)
If the taper and out±of±round is greater than maximum, replace
the crankshaft.
6. IF NECESSARY, GRIND AND HONE MAIN JOURNALS
AND/OR CRANK PINS
Grind and hone the main journals and/or crank pins to the fin-
ished undersized diameter. (See procedure in step 5) Install
new main journal and/or crankshaft pin undersized bearings.

EM08K±03
EM1321
SST
EM7329
Oil Hole
P01038
EM1322
EM±104
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
1276 Author: Date:
REPLACEMENT
1. REPLACE CONNECTING ROD BUSHINGS
(a) Using SST and a press, press out the bushing.
SST 09222±30010
(b) Align the oil holes of a new bushing and the connecting
rod.
(c) Using SST and a press, press in the bushing.
SST 09222±30010
(d) Using a pin hole grinder, hone the bushing to obtain the
standard specified clearance (See page EM±97) be-
tween the bushing and piston pin.
(e) Check the piston pin fit at normal room temperature. Coat
the piston pin with engine oil, and push it into the connect-
ing rod with your thumb.
2. REPLACE OVERSIZED (O/S) PISTONS FOR CYLIN-
DER BORING
HINT:

Bore all the 4 cylinders for the O/S piston outside diame-
ter.

Replace all the piston rings with ones to match the O/S
pistons.
(a) Keep 4 new O/S pistons.
O/S 0.50 piston diameter:
87.350 ± 87.380 mm (3.4390 ± 3.4402 in.)

P03177
Mark
1, 2, 3, 4, or 5
P05354
P03173
S06012
P00104
1
10
735
84269
± ENGINE MECHANICAL (5S±FE)CYLINDER BLOCK
EM±109
1281 Author: Date:
(b) Align the bearing claw with the claw groove of the main
bearing cap, and push in the 5 lower bearings.
HINT:
A number is marked on each main bearing cap to indicate the
installation position.
5. INSTALL UPPER THRUST WASHERS
Install the 2 thrust washers under the No.3 journal position of
the cylinder block with the oil grooves facing outward.
6. PLACE CRANKSHAFT ON CYLINDER BLOCK
7. INSTALL MAIN BEARING CAPS AND LOWER
THRUST WASHERS
(a) Install the 2 thrust washers on the No.3 bearing cap with
the grooves facing outward.
(b) Install the 5 main bearing caps in their proper locations.
HINT:
Each bearing cap has a number and front mark.
(c) Apply a light coat of engine oil on the threads and under
the heads of the main bearing cap bolts.
(d) Install and uniformly tighten the 10 bolts of the main bear-
ing cap in several passes, in the sequence shown.
Torque: 59 N´m (600 kgf´cm, 43 ft´lbf)
(e) Check that the crankshaft turns smoothly.
8. CHECK CRANKSHAFT THRUST CLEARANCE
(See page EM±86)